Kyrgios said he felt a problem with his elbow after Friday's match.
"They are the things Nick does which the public doesn't see".
Zverev had other ideas.
Zverev produced some superb tennis to down Kyrgios 6-2, 7-6, 6-2 in one hour, 48 minutes to put Germany into a quarter-final against either Spain or Great Britain.
Zverev was in sublime form against Kyrgios.
Australia team captain Lleyton Hewitt said the injury - not the must win situation - had made it hard for Kyrgios to focus. Davis Cup has become a huge focal point for Kyrgios, while the mentoring of Hewitt and the support of the team has been critical in his growth on and off the court.
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However, Barcelona's 22nd game unbeaten broke their own club record and kept the possibility of a broken league record on track. After eliminating Espanyol from the Copa del Rey, Barcelona gets another crack at its city rival in league play on Sunday.
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Everton haven't kept a clean sheet for five games and manager Sam Allardyce will be desperate to put an end to that run. Danny Welbeck could return following a hip injury, while Santi Cazorla remains on the sidelines.
"They didn't play the best match they could have played but they still fought, but came up short - I wasn't thinking about that at all". "It just leaves a bit of a bitter taste in my mouth after the Aussie summer I had", Kyrgios said.
Kyrgios made 34 unforced errors against the big-serving Zverev, who made him pay. "They know they can't win without me and I know they can't win without me", the three-time ATP victor said. "It's obviously frustrating. Two of those five-set losses could have gone either way (but) that's Davis Cup tennis, " Hewitt said.
Seppi had a match point on the Sugita serve at 6-5 but the Japanese player saved it and took the match into a tie-break. "My biggest weapon (serve) was not really there and that affects the rest of my game", he said.
Hewitt has poured his heart and soul into the Davis Cup but has some thinking to do after the weekend.
The former World No. 1 praised the polarising 22-year-old for his input in young gun Alex de Minaur's development as the 18-year-old star prepared for a national debut.
On Saturday, Tim Puetz and late call-up Struff gave Germany its 2-1 lead, beating Matt Ebden and John Peers 6-4 6-7 (1) 6-2 6-7 (4) 6-4.
The loser will contest September's World Cup playoffs.